Knit component bonding

Abstract

A composite structure may include a knit component and a bonded component. The knit component has a first surface and an opposite second surface, and the knit component includes a fusible yarn and a non-fusible yarn that form a knitted structure. The fusible yarn is at least partially formed from a thermoplastic polymer material, and the fusible yarn is located on at least the first surface. The bonded component is positioned adjacent to the first surface, and the bonded component is thermal bonded to the first surface with the thermoplastic polymer material of the fusible yarn.

What is claimed is: 
     
       1. A composite structure comprising:
 a knit component having a first surface and a second surface opposite the first surface, the knit component including a first yarn and a second yarn knitted together in a knitted structure, the first yarn comprising a thermoplastic polymer material, wherein the first yarn is located on at least a portion of the first surface of the knit component; and 
 a bonded component positioned adjacent to the first surface of the knit component, wherein the bonded component is thermally bonded to the thermoplastic polymer material of the first yarn on the first surface of the knit component, a first surface of the bonded component comprising a plurality of apertures. 
 
     
     
       2. The composite structure recited in  claim 1 , wherein the first yarn includes a core and a sheath extending at least partially around the core, wherein the sheath includes the thermoplastic polymer material. 
     
     
       3. The composite structure recited in  claim 1 , wherein the second yarn extends from the first surface of the knit surface to the second surface of the knit component. 
     
     
       4. The composite structure recited in  claim 1 , wherein the knitted structure of the knit component includes a plurality of first interlocked loops that substantially define the first surface of the knit component and a plurality of second interlocked loops that substantially define the second surface of the knit component. 
     
     
       5. The composite structure recited in  claim 1 , wherein the first yarn and the second yarn are plated and run parallel to each other in at least a portion of the knit component. 
     
     
       6. The composite structure recited in  claim 1 , wherein the first surface of the knit component includes a first area including the first yarn and a second area, wherein the second area is substantially free of the first yarn. 
     
     
       7. The composite structure recited in  claim 6 , wherein the bonded component is thermal bonded to the first area. 
     
     
       8. The composite structure recited in  claim 1 , wherein the bonded component is one of a knit textile material, a polymer foam element, and a polymer sheet. 
     
     
       9. An article of footwear having an upper and a sole structure, the upper comprising:
 a knit component extending through at least a portion of a length of the article of footwear, the knit component including a first surface and a second surface opposite the first surface, and the knit component including a first yarn and a second yarn knitted together to form a knitted structure, the first yarn comprising a thermoplastic polymer material, and the first yarn being located on at least a portion of the first surface of the knit component; and 
 a bonded component that is independent of the knitted structure, wherein the bonded component overlays the first surface of the knitted structure of the knit component and is thermally bonded to the first surface of the knitted structure with the thermoplastic polymer material of the first yarn, a first surface of the bonded component comprising a plurality of apertures. 
 
     
     
       10. The article of footwear recited in  claim 9 , wherein the first surface of the knit component forms at least a portion of an exterior surface of the article of footwear. 
     
     
       11. The article of footwear recited in  claim 10 , wherein the bonded component is a heel counter extending from a lateral side to a medial side of the article of footwear in a heel region of the article footwear. 
     
     
       12. The article of footwear recited in  claim 10 , wherein the bonded component is a toe guard extending from a lateral side to medial side of the article of footwear in a forefoot region of the article of footwear. 
     
     
       13. The article of footwear recited in  claim 10 , wherein the bonded component is indicia located on a side of the article of footwear. 
     
     
       14. The article of footwear recited in  claim 9 , wherein the first surface of the knit component forms at least a portion of an interior surface of the article of footwear, wherein the interior surface defines at least a portion of a void within the upper configured to receive a foot of a wearer. 
     
     
       15. The article of footwear recited in  claim 14 , wherein the bonded component is a knit textile. 
     
     
       16. The article of footwear recited in  claim 9 , wherein the first yarn includes a core and a sheath extending at least partially around the core, wherein the sheath comprises the thermoplastic polymer material. 
     
     
       17. The article of footwear recited in  claim 9 , wherein the second yarn extends from the first surface of the knit component to the second surface of the knit component. 
     
     
       18. The article of footwear recited in  claim 9 , wherein the first yarn and the second yarn are located (a) at the first surface of the knit component, (b) at the second surface of the knit component, and (c) between the first surface and the second surface of the knit component. 
     
     
       19. An article of footwear having an upper and a sole structure, the upper comprising:
 a base component extending through a length of the article of footwear and defining an exterior surface facing outward from the article of footwear, and an interior surface defining at least a portion of a void within the upper configured to receive a foot of a wearer, a first surface of the base component comprising a plurality of apertures; and 
 a knit component having a first surface and a second surface opposite the first surface, the knit component including a first yarn and a second yarn knitted together to form a knitted structure that is independent of the base component, wherein the first yarn is located on at least a portion of the first surface of the knit component, and the first yarn comprises a thermoplastic polymer material, and wherein the base component overlays the first surface of the knit component and is thermally bonded to the thermoplastic polymer material of the first yarn. 
 
     
     
       20. The article of footwear recited in  claim 19 , wherein the base component comprises a knit textile.